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A new flash (ultra-rapid) spark plasma sintering method applicable to various materials systems, regardless of their electrical resistivity, is developed. A number of powders ranging from metals to electrically insulative ceramics have been successfully densified resulting in homogeneous microstructures within sintering times of 8-35 s. A finite element simulation reveals that the developed method, providing an extraordinary fast and homogeneous heating concentrated in the samples volume and punches, is applicable to all the different samples tested. The utilized uniquely controllable flash phenomenon is enabled by the combination of the electric current concentration around the sample and the confinement of the heat generated in this area by the lateral thermal contact resistance. The presented new method allows: extending flash sintering to nearly all materials, controlling sample shape by an added graphite die, and an energy efficient mass production of small and intermediate size objects. This approach represents also a potential venue for future investigations of flash sintering of complex shapes.
Graphite creep has high importance for applications using high pressures (100 MPa) and temperatures close to 2000 {textdegree}C. In particular, the new flash spark plasma sintering process (FSPS) is highly sensitive to graphite creep when applied to
This work addresses the two great challenges of the spark plasma sintering (SPS) process: the sintering of complex shapes and the simultaneous production of multiple parts. A new controllable interface method is employed to concurrently consolidate t
An energy efficient spark plasma sintering method enabling the densification of large size samples assisted by very low electric current levels is developed. In this method, the electric current is concentrated in the graphite foils around the sample
The 3 heating modes are utilized to make ZrN powders have 3 different levels of the electric current density at the same temperature during spark plasma sintering (SPS). The constitutive equation of sintering for SPS is applied to the experimental po
Flash sintering phenomena are predominantly associated with ceramics due to thermal runaway of their electric conductivity noticeably represented in materials such as zirconia or silicon carbide. Because of their high electric conductivity, flash sin